Gravure Coating:

One of the Most Versatile Methods in the Industry

Webinar – April 26, 2012

John Looser
New Era Converting Machinery
P.O. Box 377
Hawthorne, NJ 07506
Phone: 973-413-4605
www.neweraconverting.com E-mail: john.looser@neweraconverting.com
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Webinar Outline
• Classic Gravure Coater
– Section Details
• Improvements
– Enclosed Applicator
– Sleeve System
– Cartridge Systems
• Variations
– Reverse Gravure
– Offset Gravure
– Differential Offset Gravure
– Process Handles:
• 2-Roll and 3-Roll Gravure
– Pressurized Gravure
– Two-side Coating
• Versatility
– Application Range
– Coating Types
– Products
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 Classic Gravure Coater
• Sections:
– Coating Reservoir (Pan)
Coated Incoming
Web Web – Gravure Roll (Etched Metal)
– Doctor Blade
– Impression Roll (Rubber)
Impression /
Back-up Roll
• Process:
– Coating Pick-up
Doctor
Blade
• Fill Cells
Gravure
Roll
– Wipe (Doctor) Excess
– Transfer Coating
• “Empty” Cells (Transfer Efficiency)
Coating Pan • Film Split

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 Classic Gravure Coater

Coated Incoming
Web Web • Terminology:
– Direct Gravure
– Forward Application
Impression /
Back-up Roll • Synchronous Rotation
– Pan Fed
Doctor
Blade

Gravure
Roll

Coating Pan

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Classic Gravure Coater

• Coating Reservoir
– Enclosed Applicator Shown
• Gravure Roll
– Motor Driven
– Pneumatically Positioned
• Doctor Blade
– Integral to Enclosed Applicator
• Impression Roll
– Nip/Web Driven

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 Coating Pan
Doctor
Blade
• Function: Delivers Coating to Gravure Roll
Gravure • Maintain Constant Level
Roll
– Stand Pipe or Overflow Weir
• Consistent Coating Movement
– Continuous Recirculation
Supply Return – Foam Management
– Avoid Solids Settling
Doctor
Blade • Enclosure / Covers
Gravure – Minimize Solvent Evaporation
Roll
– Contain Slinging
• Pneumatic Pan Lift

Return Return
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Supply
 Gravure Roll
• Function: Deliver Consistent Coating
– Homogeneous Transfer (Across and Down Web)

• Etched / Patterned Cylinder

– Determines Coat Weight and Appearance
– Cell Creation: Mechanical / Laser / Electronic

• Driven Roll
– Tension Control
– Idle Mode
– Vector or Servo Controlled

• Cored for Temperature Control

– Heat Management
– Viscosity Control

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Cell Creation – Gravure Patterns
• Cell - Coating Reservoir
– BCM: Volume = Billion Cubic Micron per Square Inch
• 2 – 200 BCM

– LPI: Cell Density = Lines Per Inch

• 10 – 1500 LPI

– Release / Transfer Rate

• % Coating Volume Released Onto Substrate

– Patterns / Shapes
• Appearance and Flow
• Promote Release

• Methods for Cell Creation

– Mechanical Engraving
– Laser Engraving
– Electronic Engraving

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 Cell Creation – Mechanical Engraving
• Roll Design
– Steel Core with Soft Copper Layer
– Chrome Plating Over Pattern

• Cell Creation
– Patterned Tooling Stamps/Forms
Shapes
– Material is NOT Removed
• Surface is Re-Formed

– Roll Precision Can Be Affected

• Release Characteristics
– Most Angles are 45o
– High Surface Tension
– Average Release 40-50%

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 Mechanical Engraving – Common Shapes

Improving Release Properties

Pyramid Quadragravure

Roto-Flo Pyramid Quad Roto Flo

Tri-Helical Quad Channel 10

 Cell Creation – Laser Engraving
• Roll Design
– Steel Core with Ceramic Covering

• Cell Creation
– Focused Pulses Create Shape
– Laser Vaporizes Surface Material

• Release Characteristics
– Relatively High Surface Roughness
– Medium Surface Tension
– Average Release 50-60%

Multi-Hit Single-Hit

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 Laser Engraving – Common Shapes

Improving Release Properties

60o Hex 30o Hex

Tri-Helical 30o Channel

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 Cell Creation – Electronic Engraving
• Roll Design
– Steel Core with Hard Copper
Layer
– Chrome Plating Over Pattern

• Cell Creation
– Electronically Positioned
Diamond Tip Stylus
– Material is Precisely Removed
– Roll Precision is Maintained

• Release Characteristics
– Low Surface Tension
– Average Release 65-75%

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Electronic Engraving – Common Shapes

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 Doctor Blade
• Function: Remove Excess Coating
– Coating in Cells Only
– Cell Determines Coat Weight Trailing Blade
• Angle of Attack
25-30o
– Trailing Blade Gravure
Roll
• Low Speed / Low Viscosity
• Hydraulic Forces Can Lift Blade
• Traps Contaminates
– Reverse Angle / Chisel / Plowing Coating Pan

• Increased Speed and Viscosity

• Hydraulic Force Helps Hold Blade Reverse Angle
• Rejects Contaminates
30o

• Loading Pressure
Gravure
– 0.5 – 4.0 pli Roll

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Coating Pan
 Doctor Blade
• Materials
– High Carbon Spring Steel
– Stainless Steel
– Mylar
– UHMW
– …………

• Different Shapes
– Most Common = Simple Bevel
 Typical Blade Holder
• Pneumatically Loaded
– On/Off Control

• Angle Adjustment
– Coarse: Trailing and Reverse
– Fine: Attack Angle

• Oscillation
– Motor Driven

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 Impression Roll
• Supports Substrate
– Rubber Covered Roll
– 65-90 Shore A Durometer

• Nip Footprint
– Impression: 0.25” – 0.375”
Impression Roll
• Controls Coating Width Web

– Undercut Roll
– Lift Edges Off Gravure Roll
Gravure Roll
– Unique Roll for Each Web Width

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 Impression Roll
• Impact on Coating Quantity and Quality
– Roll Durometer Impacts Amount of Coating Transferred
• Thick Soft Covering (60-70 duro) = Large Footprint = More Coating
• Thin Hard Covering (80-90 duro) = Small Footprint = Less Coating
– Higher Precision Leads to Better Coating Uniformity
• Soft Roll = .002 - .004” TIR
• Hard Roll = .0005” - .001 TIR

– Thin Precision Coating

• Hard Cover – Small Footprint – Precision Roll
 Impression Control
• Pressure Only
– Pressure in Loading Cylinders Set
Impression
– No Position Stops Between Rolls
– Difficult to Control
• Cylinders Lift Roll / Pan / Motor AND Sets
Impression
• Pressure Changes Impact Impression

• Adjustable Stops
– Cylinders are Utilized for Positioning
– Stop Setting Dictates Impression
– High Loading Pressure = Stability
– Fine / Repeatable Adjustment
• Stop Configurations
– Coarse Thread
– Differential Screw
– Taper Wedge Block 20
Improvements
• Enclosed Applicator
• Sleeve System
• Cartridge Systems

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 Enclosed Applicator
• Enclosed System
– No Slinging of Coating
Coated Incoming
– Minimizes Solvent Evaporation Web Web

– Reduced System Volume

• High Rate of Recirculation
Impression /
– Minimizes Air Entrapment Back-up Roll

– Foam Control – Flows Out of

Chamber
• Easy to Clean
Gravure
– Simple Flushing Systems Roll

– Minimize Waste
Return

Supply
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Enclosed Applicator

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Impression Roll: Sleeve System

• Impression Roll:
– Rubber Covered Sleeve
– Steel Mandrel

• Drive Side
– Cantilever Support

• Operator Side
– Removable Bearing Support

• Quick Width Change

– 5 Minute Task

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Impression Roll: Sleeve System

• Air Pressure Expands Sleeve

– Floats Off Mandrel

• Straight or Tapered Mandrel

• Sleeves
– Nickel
– Composite

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Cartridge System
• Base Frame and Drive Stand
Fixed in Web Line
• Gravure Roll, Impression Roll
and Coating Applicator on
Cartridge
• Quick Change System
– Off-Line Clean-up
– Coating Change
– 10 Minute Change-out Time
• Typical Features
– Precision Rails Maintain
Alignment
– Quick Connects for Air and
Electrical
– Tool-less Quick Disconnect Drive
Coupling 26
Cartridge System

• Base Frame with Applicator Roll,

Impression Roll and Drive Stand
Fixed in Web Line
• Gravure Cartridge Installed
• Five Motors on Drive Stand
• 5-Roll Transfer Coating
– Two Rolls on Base
– Three Rolls on Cartridge
• Quick Change System
– Switch Between Methods
– Clean-up Off-Line
– 10 Minute Change-out Time

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 Variations
• Reverse Gravure
• Offset Gravure
• Differential Offset Gravure
• Pressurized Applicator
• Two-Side Coating

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 Reverse Gravure
• Reverse Application
– Speed Range: 90-120%
Coated Incoming
Web Web
• Benefits
– Removes Cell Pattern

Impression /
– Film Split Avoided
Back-up Roll • Minimizes Ribbing
– Adjust Coat Weight with Roll
Doctor Speed
Blade
• Impression Control is Critical
Gravure
Roll – Light / Controlled Impression
– Precision Required – Better Rolls
• Driven Impression Roll
Coating Pan
– Suggested for Tension Control
– Overcome Reverse Action
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 Offset Gravure
Coated
Web
Incoming
Web
• 3-Roll System
– Gravure is Offset from Substrate
Steel – Removes Substrate from Coating Nip
Back-up Roll
• Protects Sensitive Substrates

Film
• Roll Rotation
Split
– All Roll Same Direction
Rubber
• Synchronous Rotation
Applicator Roll
“Forward”
– Two Film Splits
– Thinner Coatings
Film
Doctor
Blade
Split • Roll Speeds
Gravure – All Rolls at 100% Line Speed
“Forward”
– Single Drive is Possible
• Gravure Roll is Typically Driven – Idle Mode
• Applicator Roll is Nip Driven
Coating Pan • Back-up Roll is Web Driven

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 Differential Offset Gravure
Coated Incoming
Web Web • 3-Roll System
• Roll Rotation
Steel
Back-up Roll – Gravure: Forward / Reverse
– Applicator: Forward / Reverse
Film
Split • Roll Speeds
Rubber
– Gravure: Variable
Applicator Roll
Fwd / Rev
– Applicator: Variable
– Back-Up: Controls Tension
Film
Doctor Split
– All Rolls are Driven
Blade

Gravure
• Roll Function
Fwd / Rev – Gravure: Coat Weight Control
– Applicator: Appearance Control

Coating Pan

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Differential Offset Gravure

• Cartridge Coater
• All Driven Rolls
– Additional Drives for 5- Roll Coating

• Wide Range of Set-ups

– Gloss Top Coat
• Gravure = 100%, Applicator = 100%

– Silicone Coating
• Gravure = 5%, Applicator = 95%

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Process Handles: 2-Roll Gravure
Coat Weight and Appearance

• Direct Gravure - Forward Application

1. Gravure Roll Selection
2. Gravure / Back-up Roll Nip Footprint

• Direct Gravure – Reverse Application

1. Gravure Roll Selection
2. Gravure / Back-up Roll Nip Footprint
3. Gravure Roll Direction
4. Gravure Roll Speed

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Process Handles: 3-Roll Gravure
Coat Weight and Appearance

• Offset Gravure
1. Gravure Roll Selection
2. Gravure / Applicator Roll Nip Footprint
3. Applicator / Back-up Roll Nip Footprint

• Differential Offset Gravure

1. Gravure Roll Selection
2. Gravure / Back-up Roll Nip Footprint
3. Applicator / Back-up Roll Nip Footprint
4. Gravure Roll Direction
5. Gravure Roll Speed
6. Applicator Roll Direction
7. Applicator Roll Speed

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Pressurized Coating Applicator

Pressurized Applicator Tri-Helical Gravure Roll

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 Pressurized Coating Applicator

Conventional Applicator: Pressurized Applicator: Pressurized Applicator:

No Pressure Low Pressure Higher Pressure

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Pressurized Coating Applicator
• Adjustable Coat Weight with a Single Cylinder
– 50-100% Weight Increase
– Reduced Gravure Roll Inventory

• Extended Coat Weight Range

– Thicker Coatings

• Constant Coat Weight with Increasing Speed

– More Efficient in Filling Gravure Cells
– Less Recirculation and Foam Generation

• Higher Viscosity and % Solids

Pressurized
Applicator

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Simultaneous Two-Side Coating

• Very Cost Effective

– Coat Both Sides at One Coating Station
– Single Dryer vs. Dual Dryers
– Reduced Overall Line Length
• Direct Application (Kiss Coating)
Gravure – Forward or Reverse Apply
Roll
– Coat Weight is Susceptible to Tension
Variations
• Limited Range of Applications
Gravure
Roll – Thinner Coatings
– Same / Similar Functional Coatings on
Both Sides
 Two-Side Coating

Applicator
Roll
Gravure Gravure
Roll Roll
Applicator
Roll
Applicator
Roll
Gravure
Roll Applicator
Roll
Gravure
Roll

• Offset Coat • Offset “Kiss” Coat

– Supported – Unsupported
Versatility
• Application Range
– Speeds: 0 - 2000+ fpm
– Widths: 0 - 200+ inches
• Substrates:
– Papers
– Boards
– Films
– Foils
– Wovens / Non-wovens
– ………
• Coating Types:
– Water Based
– Solvent Based
– 100% Solids (UV and E-Beam Cure)
– Hot Melt: Adhesives and Waxes
– ………

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 Versatility
• Viscosity and Wet Coating Thickness:
– 2-Roll Gravure:
• 10-1000 cps
• 0.0005” – 0.0015”
– 3-Roll Gravure
• 50 – 2000 cps
• 0.0001” – 0.001”
– Pressurized Gravure
• 100 – 5000 cps
• 0.0005” – 0.005”

• Coatings:
– PSA’s: Solvent, Aqueous and Hot Melt
– PVDC and other Barrier Coatings
– Primer Coats
– Topcoats: High Gloss and Protective
– Laminating Adhesives
– Silicones: Solvent, Aqueous, 100% Solids
– ……….. 41
 Versatility
• Top Coats for Wear Resistance on
Magazines
• Gloss / Color Snap Coatings for
Automotive Brochures
• Adhesives for Wood Grain Patterned
Coverings on Furniture
• Gas Emissive Coatings for Medical
Packaging
• Protective Coatings on Appliance
Overlay
• Optically Clear Adhesives for
Protective Window Films
• Silicone Based Release Liners for
Medical Bandages
• Pressure Sensitive Adhesives for
Medical Bandages
• Lamination Adhesives for Medical
Drapery
• Primer Coatings for Aluminum Layer
in Cigarette Packaging
• Optically Clear Adhesives for Bottle
Labels
• Adhesives on Masking Films
• Reactive Coatings on Thermal
Papers
• Pre-Paste on Wall Coverings
• Tinting of Decorative Fabrics
• Laminating Adhesives for Lottery
Tickets
• Bonding Layer for Foam / Fabric
Headliners 42
 Questions?

Thank You!
Graphic References
• Doctor Blades
– Benton Graphics
• Gravure Roll Slides:
– Zecher
– Pamarco
• Enclosed Applicator
– Harris and Bruno

www.neweraconverting.com
John Looser
New Era Converting Machinery
P.O. Box 377
Hawthorne, NJ 07506
Phone: 973-413-4605
E-mail: john.looser@neweraconverting.com
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